Method and device for producing shaped sheet-metal components by means of preformed components

ABSTRACT

A method for producing a component in which a workpiece is preformed to form a preformed component and a finally shaped component is produced from the preformed component. The preformed component is formed into a singly or multiply offset finally shaped component by a forming process. The invention furthermore relates to a device with a forming tool. The forming tool is designed as a multi-part forming tool in which each part of the multi-part forming tool includes at least one punch and one die. The forming tool is designed to produce a singly or multiply offset finally shaped component by shaping from the preformed component.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation of PCT/EP2017/075518, filed Oct. 6, 2017, the entire teachings and disclosure of which are incorporated herein by reference thereto.

FIELD OF THE INVENTION

The present invention relates to a method for producing a component, in particular a structural component of a vehicle, wherein the method comprises the method steps of preforming a workpiece into a preformed component and producing a finally shaped component from the preformed component. The invention furthermore relates to a device, in particular for carrying out the method according to the invention, with a forming tool.

BACKGROUND

Components produced by sheet metal forming, for example deep-drawn components, generally require a final edge trimming, in which excess regions of the deep-drawn component for example, are cut off. In the case of flanged parts this can be performed for example by using one or more trimming tools, which partially or fully trim the flange from above or slanting in the desired manner. In the case of flangeless parts on the other hand the trimming is already much more complicated, since it must be cut from the side, guided for example by a wedge gate valve. The trimming operations are disadvantageous however, since the trimming generally requires one or even several separate, often maintenance-intensive operations, which often also require their own tool technology and their own logistics system. In addition the cut-off portions increase the amount of scrap, resulting in additional costs.

In order at least to shorten the process chain, different approaches have been followed, with which inter alia the flange trimming was integrated into the last forming operation, for example deep-drawing operation. Although significant cost savings can be achieved in this way, some disadvantages still exist however, such as the occurrence of waste cuts, the creation of complicated tools, an extensive testing, unwanted spring-back effects, limited dimensional accuracy and a susceptibility to process disturbances.

For this reason methods and devices have been proposed in order to save or greatly reduce the edge trimming of components, in particular having a U-shaped or hat-profile-like cross section.

Proposed methods are characterised in that preformed components largely close to the final contour are produced by various methods of forming, which by means of suitable geometric variations such as extensions of the borders and flanges, undulating floors or modified drawing radii, mainly have a flat material allowance. In the following special calibration step this material addition is squeezed out, which leads to thickening and realignment of the residual stresses in the direction of the sheet plane. Modifications of these methods operate with combined variants, in which a material shortage may also exist in some sections. Local trimming operations before or after the calibration are also possible. In addition to minimising the spring-back, the aim is also to reduce the trimming. Thus, a finished component completely free of edge trimming can be fabricated from a preformed component close to the final contour and can thus be manufactured with minimal use of material from shaped blanks of minimal dimensions, so-called minimal shaped blanks.

For example, from DE 10 2007 059 251 A1 it is known to produce highly dimensionally accurate half shells in a two-stage process. For this purpose preformed half shells largely close to the final contour are first produced, which have excess material over the entire cross-section due to their geometrical shape. The preformed half shells are then compressed by a further pressing process compressed into their final shape. A half shell produced in this way has a particularly high degree of dimensional accuracy, since the residual stress component generating the spring-back of the half shell is superimposed or reduced by the introduced compression.

A disadvantage of this production process, however, is that the preformed half shells usually have to be subjected to a further trimming, so that they have the desired dimensions, in particular with regard to the border height. In order to optimise the process chain, it is known for example from DE 10 2011 050 001 A1 to integrate the final trimming into the deep-drawing process. To produce flangeless drawn parts, according to this document the flange region of the half shell is trimmed in the region of the die contact surface. The preformed half shell produced in this way is then calibrated in the same tool by means of a compression shoulder arranged on the drawing die. However, this method also has the disadvantage that excess blank material occurs as waste, and the integration of the cutting edge into the deep-drawing die leads to a very high tool wear. In addition, it cannot be adequately ensured that the blank does not change its position during the deep-drawing, whereby the dimensions of the half shell are inaccurate, which in turn requires trimming in the flange or border region.

German published application DE 10 2008 037 612 A1 also describes a method for producing highly dimensionally accurate half shells with a bottom region, a border region and a flange region, wherein a preformed half shell is first of all formed from a blank, which is then shaped and trimmed into the finally shaped half shell.

German published patent application DE 10 2009 059 197 A1 describes a method for producing a half shell part with a drawing punch and a drawing die. A process-reliable and cost-effective production is achieved by inserting the drawing punch into the die in a single work step, preforming a blank into a sheet metal blank with at least one base section, at least one border section and optionally a flange section, wherein during the preforming excess material is introduced with the punch either into the bottom section and the border section or the optional flange section of the sheet metal blank, and the sheet metal blank is formed and calibrated into a half shell part having the final shape.

The approaches described have in common that a preform is produced in a first method step, wherein the preform is as close as possible to the final shape or finished shape of the component and an additional edge trimming may be necessary.

The reduction or elimination of edge trimmings requires robust and less sensitive preforming methods that deliver components that as far as possible are independent of friction and batch and thickness fluctuations, and whose processing differs only slightly from one another. As described, this is carried out by using distanced outer hold-down devices, clamping-type inner hold-down devices, as well as larger drawing gaps and drawing radii.

Only where this approach does not work on account of the formation of significant folds or cracks, are edge contour additions, braked hold-down devices or small drawing radii necessary, which thereby create additional excess regions.

In the course of the realisation of real components it has now been found that the currently known approaches to preform design are not always sufficient in order to produce challenging component shapes or minimise trimming. Thus for example, relatively strongly offset preforms for U-beams, such as are encountered for example in vehicles, can be preformed only by conventional deep drawing followed by trimming. This requires more material and reduces the savings effect.

BRIEF SUMMARY

Against this background, the present invention is based on the object of providing a method and a device for the cost-effective production of components of complex shape.

As a departure from the hitherto conventional technical development, this object is achieved in a generic method in which the preformed component, in particular a component far from the final contour, is turned into a singly or multiply offset (in particular in the longitudinal direction) finally shaped component or into a singly or multiply offset finally shaped, highly dimensionally accurate component, by a forming operation, in particular in at least one process step. Thus, in a preforming step in a first tool or optionally several tool stages simple components that in particular are far from the final contour but that can be easily produced can first of all be preformed by means of a slightly sensitive fabrication, in which the edge contour deviates rather slightly from the target contour. In a further method step the finally shaped component can then be produced in at least a second tool by forming from the preformed component. The method according to the invention has the advantage that, for the production of components, in particular components of complex shape, substantially flat blanks or minimally shaped blanks can be used and yet edge trimming can be largely dispensed with, so that a significant simplification of the manufacturing process compared to the known methods is achieved.

The workpiece is for example in this connection a substantially flat blank or minimal shape blank. The workpiece is preferably produced from one or more steel materials. Alternatively, aluminium materials or other metals can also be used.

A preformed component, particularly a component far from the final contour, is understood to mean in particular a preform of a component that cannot be formed into the finished component simply by a calibration. For example, the preformed component or component far from the final contour is a substantially straight component. Of course, the preformed component or component far from the final contour may already have structured surface elements. If the finally shaped component is for example an offset component, the preformed component or component far from the final contour is for example a less offset or non-offset component. For example, the preformed component or component far from the final contour in at least one direction, for example in the longitudinal direction, has in contrast to the finally shaped component a substantially constant cross-sectional geometry. In particular the preformed component or component far from the final contour can, on account of its remote final contour in contrast to the finally shaped component, be manufactured in a simple and material-saving manner that is more process-reliable by embossing the floor to be created and raising the borders to be created (embossing and raising). Alternatively, effective continuous methods such as roll forming can also be used. In contrast, a finally shaped, highly dimensionally accurate component is understood to mean in particular a component that has been subjected to calibration.

The production of the preformed component, in particular of the component far from the final contour, can include for example a deep-drawing-like shaping step, in which for example a deep-drawing tool with an inner hold-down device, a distant outer hold-down device and/or large drawing radii and drawing gaps as well as optional aids for loading and positioning, can be used. In particular a shaping can also be carried out, including for example embossing the base and raising the borders or optionally placement of the flanges to be created. Any combinations of folding and/or bending and/or (punching) embossing or roll forming with subsequent portioning into sections are also conceivable.

According to a further embodiment of the method according to the invention, the shaping and a calibration for producing a finally shaped, highly dimensionally accurate component can be carried out in a joint method step. This embodiment has the advantage that a finally shaped, highly dimensionally accurate component can be obtained from a preformed component in only one process step, and in particular using only one tool.

Alternatively, in a further embodiment of the method according to the invention a finally shaped component is first produced from the preformed component in a further shaping step by shaping, following which a finally shaped, highly dimensionally accurate component is then produced from the finally shaped component by calibration. This two-step variant has the advantage that for example already existing calibration tools can be used to calibrate the component and the method can thus be incorporated economically into existing process chains.

If a calibration is envisaged, the preformed component or in particular the finally shaped component contains the material additions and/or material deficiencies necessary for the production of dimensionally accurate finally shaped components in particular.

Calibration can be understood to mean, in particular, the final shaping of the finally shaped component, which can also be achieved for example by one or more pressing or upsetting procedures. However, it is possible that the finally shaped or finally shaped, highly dimensionally accurate component can undergo further processing steps modifying the component, such as the introduction of connection holes, side embossing, flange placements or a (slight) trimming process. However, the aim is to design the shape of the tool used for the calibration in such a way that no further forming steps are otherwise necessary.

In a further embodiment of the method according to the invention, the preformed, finally shaped component and/or the finally shaped, highly dimensionally accurate component is a substantially elongated component. It was found that the method according to the invention can be advantageously used in particular in the production of elongated components of complex shape. Elongated components are understood to mean in particular components that have a significantly longer side compared to the other two sides and in particular have a pronounced border. This longer side naturally forms a preferred direction of the component, hereinafter referred to as the longitudinal direction, while the other two sides each represent a transverse direction. In particular, components of particularly complex shape can be produced in a particularly cost-effective manner from components that are more elongated in the longitudinal direction of these components at least by a factor of >1, in particular at least by a factor of 3, preferably at least by a factor of 5, compared to the transverse direction.

According to a further embodiment of the method according to the invention the preformed, the finally shaped and/or the finally shaped, highly dimensionally accurate component is a half shell-shaped component, which in particular is a U-shaped or hat-shaped component in cross section. It was recognised that the method according to the invention is suitable for a particularly cost-saving production of half shell-shaped components, and in particular its use in the case of components of U-shaped or hat-shaped cross-section has proved to be particularly advantageous.

According to a further embodiment of the method according to the invention, the preformed component is formed in its longitudinal direction into a finally shaped or finally shaped, highly dimensionally accurate component having a Z-shape (offset) or U-shape (double offset). The method according to the invention is particularly suitable for the production of complicatedly shaped components, such as for example offset components or even markedly offset components such as markedly offset U-shaped components, particularly if they undergo a calibration. The method according to the invention has proven to be particularly cost-saving, specifically in the production of singly offset or singly and multi-dimensionally offset components. With the method according to the invention complicatedly shaped components can thus be produced with minimal shaped blanks, so that edge trimming can largely be dispensed with if necessary. Especially when the components have a Z or U shape in the longitudinal direction, they can be manufactured in a particularly material-saving way. The Z shape is in this case generated for example by a displacement of in each case oppositely facing shape sections about a middle region, so that the regions of the preformed component to be changed are disposed at defined angles to the direction of displacement, for example if the longitudinal direction or the longitudinal axis runs in the X direction, a displacement in the Z and/or Y direction is possible (coordinate system). Depending on the nature of the offset the displacement along the longitudinal axis of the component can also occur repeatedly and in opposite directions. U-shaped or multiply offset variants of the finally shaped component or the finally shaped, highly dimensionally accurate component are then obtained.

According to a further embodiment of the method according to the invention, different regions of the preformed component are shaped and/or calibrated time-delayed into the finally shaped or finally shaped, highly dimensionally accurate component.

Different regions of the preformed component are therefore at least partially not shaped or calibrated at the same time into the final formed shape or final formed, highly dimensionally accurate shape, wherein a final formed shape is understood to mean the shape of the final formed component and a final formed, highly dimensionally accurate shape is understood to mean the shape of the finally shaped, highly dimensionally accurate component. The different regions can partially overlap or can be completely different regions. Different regions of the preformed component are thus at least partially individually or separately shaped or calibrated. The shaping of the preformed component or the calibration consists in particular of partial shaping or calibration steps. There is preferably a partial time overlap between the shaping and/or calibration of different regions, so that the shaping and/or calibration takes place partly at the same time. However, it is also possible that a shaping and/or calibration of a region takes place only when the shaping and/or calibration of the previous region is complete. For example, at least a first region and a second region are envisaged, which are shaped and/or calibrated at different times. However, more than two, for example three, four, five or more different regions can also be envisaged. This procedure provides a further cost saving in the production of complicated components. In particular, the cost-saving use of, for example, a single tool and/or the use of a low-maintenance tool in the further shaping step and/or in the final shaping can thus be achieved. In particular, the range of applications can be expanded to include components that in particular have not been able to be satisfactorily manufactured using the boundary conditions of the method known from the prior art, for example because of their complex shape.

In a further embodiment the finally shaped or finally shaped, highly dimensionally accurate component has at least three regions, in particular an offset middle region with two adjacent edge regions, wherein the edge regions are and/or remain preferably aligned substantially parallel when the preformed component is formed into the finally shaped or finally shaped, highly dimensionally accurate component and the longitudinal axis of the middle region is angled with respect to the longitudinal axis of the edge regions. Other orientations of the edge regions are also possible in the X, Y and/or Z direction (coordinate system). The term edge region refers in this context to the fact that such a region is arranged next to a middle region and is not dependent on the absolute position of this region in the entire finally shaped component. It was found that the method according to the invention is particularly advantageous for the production of components of such complicatedly shaped components. If the end shaped component also has an angle of 10° to 120°, in particular an angle of 20° to 100°, preferably an angle of 25° to 90° between the longitudinal axis of at least one edge region and the longitudinal axis of the at least one middle region, the complexity and control of the tool for the forming and/or calibration can be kept as low as possible. Particularly preferably, the finally shaped or finally shaped component also has an angle of 30° to 60° between the longitudinal axis of at least one edge region and the longitudinal axis of the at least one middle region, so that the complexity of the tool can be further reduced.

According to a further embodiment of the method according to the invention, a multi-part forming tool is used, wherein the middle region of the preformed component is formed into a final shape after at least one edge region of the preformed component has been formed into a final shape, or wherein the middle region of the preformed component is shaped and calibrated into the finally shaped, highly dimensionally accurate shape after at least one edge region of the preformed component has been formed and calibrated into a finally shaped, highly dimensionally accurate shape.

In a preferred embodiment of the method according to the invention the preformed component is placed in dies which are arranged inclined to the direction of displacement of the punches or dies used for the forming. The direction of displacement is understood in particular to mean the direction of movement of the punches and/or dies during the shaping process, thus for example the vertical direction. A die arranged inclined with respect to the vertical direction is understood in particular to mean that the longitudinal axis of the inserted component is inclined relative to the direction of displacement. It was recognised that the degree of ironing can advantageously be adjusted via the angle between the direction of displacement and position of the component. The smaller the angle, the greater the ironing that can be achieved. The desired degree of ironing can thus be adjusted in a cost-saving manner by using a single tool.

In a further advantageous embodiment of the method according to the invention, the preformed component is clamped between at least one edge die and the associated at least one edge punch, wherein the clamping force is so high that the preformed component essentially cannot slip (i.e. not slip or only slightly). By adjusting the clamping force a production of complicatedly shaped components can thus be achieved with relatively little effort.

According to a second teaching of the present invention, the object is achieved in a generic device in that the forming tool is designed as a multi-part forming tool, wherein each part of the multi-part forming tool comprises at least one punch and one die, wherein the forming tool is arranged to produce a singly or multiply offset finally shaped component by forming from the preformed component, or a singly or multiply offset finally shaped, highly dimensionally accurate component by forming and calibration from the preformed component. The device is preferably used in a transfer press or alternatively in linked individual presses.

The use of such a device enables a cost-effective production of complicated components. In particular, the cost-saving use of for example a single forming tool and/or the use of a low-maintenance forming tool in the further forming step and/or in the final forming can thus be achieved. In particular, the range of applications can be extended to components which hitherto in particular cannot be suitably produced or only with great difficulty under the boundary conditions of the method known from the prior art, for example because of their complicated shape.

The device according to the invention can also comprise a tool for producing the preformed component, in particular for example an embossing and raising tool or a deep-drawing tool with an inner hold-down device, a distanced outer hold-down device, large drawing radii and drawing gaps and/or aids for loading and positioning. The use of a roll-forming process with subsequent portioning into individual parts (preformed components) is also possible.

For the production of a finally shaped, highly dimensionally accurate component, the device according to the invention may comprise a forming tool with a calibration function, in particular having a solid or divided forming die with a calibration function and/or also single-part or multi-part forming dies with a calibration function and/or auxiliary elements for loading, support, positioning and/or ejecting.

Alternatively or additionally, the device according to the invention may have a calibration tool, in particular comprising a solid or divided calibration die and/or also one-part or multi-part calibration punches and/or auxiliary elements for loading, support, positioning and/or ejecting.

In a further embodiment of the device according to the invention the forming tool has at least one centre tool part with two adjoining edge tool parts, wherein the at least one centre tool part comprises at least one central punch and at least one centre die, and at least one of the edge tool parts comprises an edge punch and an edge die. A particularly reliable and cost-saving production using the device according to the invention can be ensured by this arrangement.

According to a further embodiment of the device according to the invention, the at least one edge die of at least one of the edge tool parts is a height-adjustable edge die. Since at least one edge die is height-adjustable, for example is mounted on spindle sleeves, the sequence of the forming and/or calibration of the different regions of the preformed component can be advantageously adjusted. For example, a shaping and/or calibration, but also a clamping of an edge region of the preformed component can take place already before or during the shaping and/or calibration of another component region (in particular a middle region), which further simplifies the production of this component, especially with highly dimensional accuracy, without edge trimming. Optionally the edge dies, especially those that are not height-adjustable i.e. edge dies already in the end position, comprise an inner holding-down device or shape-maintaining punch, which essentially supports the major part of the shape of the edge region in such a way that the shaping movement does not cause any significant dimensional change, so that the preformed component can be positioned particularly advantageously in addition to the positive engagement with the edge tool parts, and a certain dimensional accuracy can thus be generated. The term height-adjustable in the context of the edge die is understood to mean that the thus designated edge die is height-adjustable compared to other die parts of the forming tool, whereas these other die parts are rigid relative to one another.

According to a further embodiment of the device according to the invention, the at least one edge punch of at least one of the edge tool parts is movably mounted relative to the other punch (parts). Since at least one edge punch is movably mounted in a force-acting manner, preferably by means of at least one hydraulic actuating means, the sequence of the shaping and/or calibration of the different regions of the preformed component can be further advantageously adapted. For example, a shaping and/or calibration, but also clamping of an edge region of the preformed component can take place before or during the shaping and/or calibration of another component region (in particular a middle region), which further simplifies the production of these components in particular with highly dimensional accuracy without edge trimming. In combination with a height-adjustable die, the simultaneous shaping and/or calibration of the edge regions adjacent to a middle region of the preformed component can thus for example be achieved particularly advantageously. In the context of the edge punches the term movable is understood to mean that the thus-designated edge punches can be moved separately with respect to other punch parts of the forming tool according to the invention, in particular can be adjusted as regards height, whereas the other punch parts mentioned are rigid with respect to one another.

It is particularly advantageous if, according to a further embodiment, the device and/or the forming tool are in an inclined position with respect to the direction of displacement. It was recognised that the degree of ironing can advantageously be adjusted by these measures.

According to a further embodiment of the device according to the invention, the forming tool has a forming edge die with calibration function and/or a forming edge punch with calibration function, in particular a height-adjustable forming edge die with calibration function, optionally with an inner hold-down device. The shaping and calibration of the preformed component into the finally shaped component can thus advantageously be carried out with only one tool.

A forming (edge) die with calibration function and a forming (edge) punch with calibration function are understood to mean (edge) dies or punches that essentially already contain the final shape of the highly dimensionally accurate, finally shaped component.

In a further embodiment of the device according to the invention the forming tool has means for blocking the flow of material over the edge of the component, for example has lateral or end shut-off walls. A further improvement of the dimensional accuracy of the finally shaped components is thereby achieved, in particular in an optional flange region, in that the material flow of the component is shut off at least temporarily during the pressing procedure, for example at the optional flange edges of a half shell-shaped component. In this way it is ensured that no blank material is forced out from the pressing region and thus all the excess blank material is completely formed into the finally shaped component. The blocking of the material flow of the preformed and/or finally shaped and/or finally shaped, highly dimensionally accurate component to the outside can be achieved in a particularly preferred manner by a barrier wall provided on the punch used for the pressing procedure. On the one hand this has the advantage that no additional movable component has to be provided in order to shut off the material flow to the outside. On the other hand, it is achieved in this way that the shut-off wall blocking the flow of material moves precisely during the pressing procedure causing the material flow, into the position envisaged for the shut-off. Alternatively, movable side walls can provide a blocking effect. In addition the device optionally has means for clamping individual base regions of the preformed component, which thereby enables a precise positioning of the preformed component, which is particularly advantageous for the dimensional accuracy.

The previous and following description of method steps according to preferred embodiments of the method are also intended to disclose corresponding means for carrying out the method steps by preferred embodiments of the device. The disclosure of means for carrying out a method step is also intended to disclose the corresponding method step.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be explained in more detail hereinafter with the aid of two exemplary embodiments in conjunction with the drawings, in which:

FIG. 1a-d show schematic representations of the shaping of the preformed component in the finally shaped component in the context of a first embodiment of a method according to the invention with an embodiment of a device according to the invention, wherein only the effective surfaces of the punches and dies are shown, and

FIG. 2a-f show schematic representations of the shaping of the preformed component into the finally shaped, highly dimensionally accurate component in a single step in the context of a second exemplary embodiment of the method according to the invention with an exemplary embodiment of a device according to the invention, wherein only the effective surfaces of the punches and dies are shown.

DETAILED DESCRIPTION

Exemplary embodiments of the method according to the invention and of the device according to the invention are explained in more detail hereinafter based on the production of a hat-profile-like, singly offset component. An analogous procedure is employed for flangeless and/or multiply offset parts.

The same reference numerals are used hereinafter for similar or corresponding features.

In a first step, not shown, a singly shaped preformed component 1 in the form of an offset, elongated and, in the longitudinal direction, predominantly straight hat profile with a predetermined edge contour is inexpensively produced by suitable means. The term simple refers to the extension of the longitudinal axis of the preformed component, which may otherwise have fully structured further surface elements or curvatures. Suitable measures for producing this singly shaped, preformed component 1 are for example embossing and raising/turning up or robust deep drawing with a distant outer hold-down device. The device for producing the singly shaped, preformed, in particular component 1 far from the final contour is thus, for example, a tool for embossing and raising or a deep-drawing tool with an inner hold-down device, distant outer hold-down device, large drawing radii and drawing gaps, and also aids for loading and positioning. Singly shaped, preformed components 1 can alternatively also be produced by roll shaping.

The further shaping takes place in the next step in a forming tool, shown schematically in FIG. 1, according to the device in accordance with the invention. The forming tool for the further shaping of the singly shaped preformed component 1 is constructed here in three parts and comprises a centre tool part and two edge tool parts, wherein the centre tool part has a central punch 2 b and a centre die 3 b and the first edge tool part has an edge punch 2 a and a height-adjustable edge die 3 a, wherein the edge die 3 a is movably mounted in a height-adjustable manner via spindle sleeves 6. The non-height-adjustable die parts can also have an optional inner hold-down device (not shown), which when extended facilitates the positioning and loading. The second edge tool has a movable edge punch 2 c and a rigid edge die 3 c. The movable edge punch 2 c associated with the rigid edge die 3 c is movably mounted by for example hydraulic or other force-acting adjustment means, the direction of movement 5 of these force-acting adjustment means being shown relative to the other punches, namely the central punch 2 b and the edge punch 2 a of the first edge tool part. The forming tool is inclined with respect to the downward movement of a press represented by the arrow 4. The course of the further shaping is described below.

As shown in FIG. 1 a, the edge punches 2 a, 2 c and the central punch 2 b are in the raised position at the start of the further shaping step. The height-variable edge die 3 a is raised to the level of the rigid edge die 3 c by the spindle sleeves of the press, as indicated by the arrow 6. The other two dies 3 b, 3 c are already located in their end position, are rigid and are not moved. In addition the inner hold-down device (not shown) of the one fixed edge die 3 c can be extended.

Firstly, the singly preformed component 1 is inserted into the dies 3 a, 3 b, 3 c inclined to the direction of displacement 4. In this connection the preformed component can be positioned by the positive connection to the two edge dies and/or by the raised inner hold-down device, not shown, of the rigid edge die.

As shown in FIG. 1 b, the edge punches 2 a, 2 c and the central punch 2 b are afterwards lowered by the movement of the press in the direction of displacement 4. In this case first of all the force-acting movable edge punch 2 c and also the raised, height-adjustable edge die 3 a clamp the singly shaped preformed component 1 between their respective counterpart 2 a, 3 c. The clamping force is chosen so large that the singly shaped preformed component 1 cannot slip, or only slightly, during its movement. The middle region 1 b of the singly shaped preformed component 1 is initially freely exposed.

In the further downward movement the edge punch 2 a opposite the height-adjustable edge die 3 a forces the said edge die 3 a downwards. In addition the movable edge punch 2 c is blocked in its downward movement by the rigid edge die 3 c. The relative movement between the individual edge punches 2 a, 2 c and edge dies 3 a, 3 c, in conjunction with the clamping and the inclined position ensures that the middle region 1 b of the singly shaped preformed component 1 is increasingly lengthened with respect to the rigid side 1 c and thereby deflected. Since the resulting offset requires more material than the straight shape, this results in the stretching and thus associated tensile loading up to plastic deformation in almost all the transition regions between the middle region 1 b and the edge regions 1 a, 1 c of the singly shaped preformed component 1. The necessary material for this comes mainly from the stretching of the transition regions between the regions of the die division.

In the end position, as illustrated in FIG. 1 c, all die and punch parts are in a block state, which leads to the final shaping of the final-shaped component 8 (cf. FIG. 1d ), in particular leads to the displacement of the respectively opposite punch parts 2 a, 2 b, 2 c and die parts 3 a, 3 b, 3 c to a local Z shape. Depending on the type of offset, the displacement over the longitudinal axis of the component can also take place multiply and in opposite directions. This then results in U-shaped or multiply offset variants of the finally shaped component 8. In the further shaping, surface elements of the component 8 that have not yet been preformed can also be supplemented.

As shown in FIG. 1 d, the tool parts finally move into their starting position, as indicated by arrow 7, wherein the return movement direction of the force-acting adjustment means to the starting position is indicated by the arrow 5′, and the finally shaped component 8 can be removed and if necessary placed in a calibration tool, not shown, where a high degree of dimensional accuracy is established in the course of the calibration.

The optional calibration tool has in particular a solid or split calibration die and likewise one-part or multi-part calibration punches as well as auxiliary elements for loading, support, positioning and ejecting. After the calibration, the finally shaped, highly dimensionally accurate component 13 can be removed.

In a second exemplary embodiment of the method according to the invention the device according to the invention comprises only two tools, a first tool for producing the singly shaped preformed component and the forming tool for further shaping with combined calibration.

The tool for producing the singly shaped preformed component is for example the same tool as in the variant of the first exemplary embodiment, thus for example a tool for embossing and raising or for robust deep drawing with a distanced outer hold-down device or a roll forming with subsequent portioning.

As shown in FIG. 2a , the tool for the final shaping and calibration of the singly shaped preformed component comprises in combination a centre tool part and two edge tool parts, wherein the centre tool part has a central punch 2 b and a centre die 3 b, and the first edge tool part has an edge punch 2 a and a height-adjustable edge die 3 a. The second edge tool part has a movable edge punch 2 c and a rigid edge die 3 c. The height-adjustable edge die 3 a and the rigid edge die 3 c each optionally has an inner hold-down device 10. The movable edge punch 2 c associated with the rigid edge die 3 c is movably mounted by hydraulic or other force-acting adjustment means relative to the other punches, namely the central punch 2 b and the edge punch 2 a of the first edge tool part. The forming tool is in a desired inclined position with respect to the downward movement 4 of the press. In contrast to the variant from the first exemplar embodiment, the dies 3 a, 3 b, 3 c and punches 2 a, 2 b, 2 c have a calibration function, so that they are forming dies with a calibration function or forming punches with a calibration function. Furthermore, the forming tool for the calibration process has means for blocking the flow of material beyond the edge of the component, in the form of the side shut-off walls 9 and optionally front-face shut-off walls, not shown, as well as the possibility of clamping individual base regions of the preformed component 1 via the raised hold-down device 10 if required.

As in the first exemplary embodiment, the forming punches 2 a, 2 b, 2 c are initially in the raised position. The height-adjustable forming edge die 3 a is raised for example by means of the spindle sleeves of the press and optionally hydraulic or other force-acting adjusting means, the direction of movement 5 of these force-acting adjusting means being illustrated, to the level of the rigid forming edge die, indicated by the arrow 6. The other two dies 3 b, 3 c are in their end position, and are rigid and are not moved. In addition the optional inner hold-down device of both edge dies 3 a, 3 c is extended.

As shown in FIG. 2b , the singly preformed component 1 is inserted into the die. In this connection the positioning of the component 1 can be effected through the positive connection to the two edge dies 3 a, 3 c and/or through the optionally raised inner hold-down device 10 of the rigid edge die 3 c.

Furthermore, the three forming punches 2 a, 2 b, 2 c are lowered by the movement of the press punch, indicated by the arrow 4. Firstly, the force-acting mounted edge punch 2 c and also the raised, height-adjustable edge die 3 a clamp the singly shaped preformed component 1 between their respective counterpart 2 a, 3 c, i.e. parts of the die bottom or the optionally raised hold-down device 10. Since the cross section of the preformed component 1 deviates from the final shape, the clamping is initially possible only over some regions of the inner hold-down device 10. This is associated with a small spacing 12 of the bottom regions between the dies 3 a, 3 b, 3 c and punches 2 a, 2 b, 2 c, or die parts and punch parts. As can be seen in FIG. 2c , the middle region of the singly shaped preformed component 1 is initially freely exposed.

In the further downward movement the edge punch 2 a opposite the movable edge die 3 a displaces the said edge die 3 a with the raised hold-down device 10 downwards. In addition, the movably mounted edge punch 2 c is blocked in its downward movement by the rigid edge die 3 c.

Here too the relative movement between the individual edge tool parts ensures that the middle region of the singly preformed component 1 is increasingly lengthened and thereby deflected. Since the resulting offset requires more material than the straight shape and the firm clamping 11 to the raised hold-down devices 10 ensures that only a small amount of material flows from the clamped regions into the middle region, there is also stretching and thus associated tensile loading up to plastic deformation in almost all transition regions of the singly preformed component 1 between the regions of the die division, as illustrated in FIG. 2 d.

Shortly before reaching the end position, the raised hold-down devices 10 are also forced downward, as shown in FIG. 2e . The upsetting process then finally starts, in which in particular through contact with the shut-off means 9 all excess surface portions of the component 13 finally formed in the meantime are increasingly compressed.

In the end position all die and punch parts are in a block state, which leads to the final shaping of the component end contour with a high degree of dimensional accuracy and freedom from trimming.

Finally, as shown in FIG. 2f , the tool parts move into their starting position, as indicated by the arrow 7, wherein the return movement direction of the force-actuating adjusting means to the starting position is indicated separately by arrow the 5′. The finally shaped, highly dimensionally accurate component 13 can be removed and transferred to the further processing chain.

All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. 

1. A method for producing a component, in particular a structural component of a vehicle, comprising the method steps: preforming a workpiece into a preformed component, and producing a finally shaped component from the preformed component, wherein the preformed component is converted into a singly or multiply offset finally shaped component or into a singly or multiply offset finally shaped, highly dimensionally accurate component by a forming, in particular in at least one method step.
 2. The method according to claim 1, wherein a finally shaped component is first produced from the preformed component by shaping and then the finally shaped, highly dimensionally accurate component is produced from the finally shaped component by calibration.
 3. The method according to claim 1, wherein the forming and calibration for producing the finally shaped, highly dimensionally accurate component are carried out in a common method step.
 4. The method according to claim 1, wherein the preformed, the finally shaped and/or finally shaped, highly dimensionally accurate component is a substantially elongated component, in particular a component elongated in the longitudinal direction by a factor of >1, in particular at least by a factor of 3, preferably at least by a factor of 5, compared to the transverse direction.
 5. The method according to claim 1, wherein the preformed, the finally shaped and/or the finally shaped, highly dimensionally accurate component is a half shell-shaped component, in particular a component U-shaped or hat-shaped in cross section.
 6. The method according to claim 1, wherein the preformed component is formed into a Z-shaped or U-shaped finally formed or finally formed, highly dimensionally accurate component.
 7. The method according to claim 1, wherein different regions of the preformed component are shaped and/or calibrated in a time-delayed manner into the finally shaped or finally shaped, highly dimensionally accurate component.
 8. The method according to claim 6, wherein the finally shaped or finally shaped, highly dimensionally accurate component comprises at least one offset middle region with two adjacent edge regions, wherein preferably during the forming of the preformed component into the finally shaped or finally shaped, highly dimensionally accurate component the edge regions are aligned and / or remain substantially parallel and the longitudinal axis of the middle region is angled with respect to the longitudinal axis of the edge regions, in particular by 10° to 120°, preferably 30° to 90°.
 9. The method according to claim 1, wherein a multi-part forming tool is used, wherein the middle region of the preformed component is formed into a final shape after at least one edge region of the preformed component has been formed into a final shape, or wherein the middle region of the preformed component is formed and calibrated into a finally shaped, highly dimensionally accurate shape after at least one edge region of the preformed component has been formed and calibrated into a finally shaped, highly dimensionally accurate shape.
 10. The method according to claim 1, wherein the preformed component is placed in dies, which are arranged inclined to the direction of displacement of the punches or dies used for the forming.
 11. The method according to claim 1, wherein the preformed component is first clamped between at least one edge die and the associated at least one edge punch, wherein the clamping force is so high that the preformed component essentially cannot slip.
 12. A device, in particular for carrying out a method according to claim 1, comprising a forming tool, wherein the forming tool is designed as a multi-part forming tool, wherein each part of the multi-part forming tool comprises at least one punch and a die, wherein the forming tool is arranged to produce a singly or multiply offset finally shaped component by shaping from the preformed component, or is arranged to produce a singly or multiply offset finally shaped, highly dimensionally accurate component by forming and calibrating from the preformed component.
 13. The device according to claim 12, wherein the forming tool has at least one middle tool part with two adjacent edge tool parts, wherein the at least one middle tool part comprises at least one central punch and at least one central die and at least one of the edge tool parts has an edge punch and an edge die.
 14. The device according to claim 13, wherein the at least one edge die of at least one of the edge tool parts is a height-adjustable edge die and wherein the edge dies, in particular the non-height-adjustable edge dies, optionally comprise an inner hold-down device.
 15. The device according to claim 13, wherein the at least one edge punch of at least one of the edge tool parts is movably mounted with respect to the other punches, and is preferably mounted in a force-acting manner by at least one hydraulic adjusting means.
 16. The device according to claim 12, wherein the device and/or the forming tool is in an inclined position with respect to the direction of displacement.
 17. The device according to claim 12, wherein the forming tool has a forming edge die with a calibration function, in particular a height-adjustable forming edge die with a calibration function, optionally with an inner hold-down device.
 18. The device according to claim 12, wherein the forming tool has means for blocking the flow of material over the edge of the component, in particular lateral or frontal barrier walls, and/or optionally includes means for clamping individual bottom regions of the preformed component. 